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公开(公告)号：US11674207B2
公开(公告)日：2023-06-13
申请号：US17455118
申请日：2021-11-16
发明人： Robert Swartz , John Bayldon , Buckley Crist , Eugene Gore
IPC分类号： C22C47/02 , C22C47/06 , C22C47/20 , C22C49/14 , B33Y30/00 , B33Y40/00 , B29C64/194 , B29C64/205 , B29C64/165 , B22F10/10 , B22F12/00 , B22F10/66 , B22F7/04 , B29C67/00 , B33Y10/00 , B33Y80/00 , B29C64/112 , B22F10/73 , B22F12/53 , B22F10/62 , B22F3/02 , B22F3/10 , B22F7/06 , B22F7/08
CPC分类号： C22C47/025 , B22F7/04 , B22F10/10 , B22F10/66 , B22F12/00 , B29C64/165 , B29C64/194 , B29C64/205 , B29C67/00 , B33Y10/00 , B33Y30/00 , B33Y40/00 , B33Y80/00 , C22C47/062 , C22C47/20 , C22C49/14 , B22F3/02 , B22F3/1035 , B22F3/1039 , B22F7/062 , B22F7/08 , B22F10/62 , B22F10/73 , B22F12/53 , B22F2007/045 , B22F2201/01 , B22F2998/10 , B22F2999/00 , B29C64/112 , Y02P10/25 , B22F2998/10 , B22F10/10 , B22F3/02 , B22F3/1035 , C22C47/20 , B22F2998/10 , B22F10/10 , B22F3/02 , B22F3/1039 , C22C47/20 , B22F2999/00 , B22F10/10 , B22F7/08 , B22F2201/01 , B22F2999/00 , B22F10/10 , B22F7/062 , B22F2201/01
摘要： A method, product, apparatus, and article of manufacture for the application of the Composite Based Additive Manufacturing (CBAM) method to produce objects in metal, and in metal fiber hybrids or composites. The approach has many advantages, including the ability to produce more complex geometries than conventional methods such as milling and casting, improved material properties, higher production rates and the elimination of complex fixturing, complex tool paths and tool changes and, for casting, the need for patterns and tools. The approach works by slicing a 3D model, selectively printing a fluid onto a sheet of substrate material for each layer based on the model, flooding onto the substrate a powdered metal to which the fluid adheres in printed areas, clamping and aligning a stack of coated sheets, heating the stacked sheets to melt the powdered metal and fuse the layers of substrate, and removing excess powder and unfused substrate.
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公开(公告)号：US20210362421A1
公开(公告)日：2021-11-25
申请号：US17324554
申请日：2021-05-19
发明人： Robert Swartz , Eugene Gore , Buckley Crist , Darren Fill , John Bayldon
IPC分类号： B29C64/35 , B33Y10/00 , B33Y40/20 , B29C64/165
摘要： A method of residual ink removal in an ink-dependent 3-D printing process includes pre-heating a build block to an evaporation temperature. This is preferably done after stacking and before compression. Later compression will then involve a higher temperature to allow fusing of thermoplastic material in the build block, but without residual ink.
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公开(公告)号：US20210229365A1
公开(公告)日：2021-07-29
申请号：US17156565
申请日：2021-01-23
发明人： Robert Swartz , Leonard Wanger , John Bayldon , Jeff Saltzman , Charles Pint , Eugene Gore , Gintaras Vaisnys , Giovanni Meier , Alon Henson
IPC分类号： B29C64/393 , G06T7/00
摘要： A collection of camera-based monitoring sub-systems can be added to a composite-based additive manufacturing (CBAM) system to autonomously inspect the integrity of each layer and remediate issues in real time. Cameras are located at various stations throughout the process. Resulting images are analyzed to see if processed pages are within tolerance based on comparison with models. Cameras can be placed at the print platen, on a rear conveyor that conveys powdered pages to the stacker and in the stacker itself to make sure pages are stacked and aligned properly. The present invention provides quality assurance and quality control to validate the build process at the layer level. This reduces the amount of post-build labor to perform, and since it shows data internal to the part, it dramatically reduces the amount of destructive testing required.
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公开(公告)号：US10384437B2
公开(公告)日：2019-08-20
申请号：US16059275
申请日：2018-08-09
发明人： Robert Swartz , Eugene Gore , Buckley Crist , John Bayldon , Chris Wagner , Nicholas Tarzian , Evangeline Su
IPC分类号： B33Y10/00 , B29C64/165 , B33Y30/00 , B33Y40/00 , B33Y50/02 , B29B15/10 , B29C70/28 , B29C64/147 , B29C64/386 , B29C64/40
摘要： An apparatus and method for the automated manufacturing of three-dimensional (3D) composite-based objects is disclosed. The apparatus comprises a material feeder, a printer, a powder system, a transfer system, and optionally a fuser. The method comprises inserting a stack of substrate sheets into a material feeder, transferring a sheet of the stack from the material feeder to a printer, depositing fluid on the single sheet while the sheet rests on a printer platen, transferring the sheet from the printer to a powder system, depositing powder onto the single sheet such that the powder adheres to the areas of the sheet onto which the printer has deposited fluid, removing any powder that did not adhere to the sheet, optionally melting the powder on the substrate, and repeating the steps for as many additional sheets as required for making a specified 3D object.
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公开(公告)号：US20180345648A1
公开(公告)日：2018-12-06
申请号：US16059275
申请日：2018-08-09
发明人： Robert Swartz , Eugene Gore , Buckley Crist , John Bayldon , Chris Wagner , Nicholas Tarzian , Evangeline Su
IPC分类号： B33Y10/00 , B29C64/165 , B29C64/40 , B29C64/386 , B29C64/147 , B29C70/28 , B29B15/10 , B33Y50/02 , B33Y40/00 , B33Y30/00
CPC分类号： B33Y10/00 , B29B15/105 , B29C64/147 , B29C64/165 , B29C64/386 , B29C64/40 , B29C70/28 , B33Y30/00 , B33Y40/00 , B33Y50/02
摘要： An apparatus and method for the automated manufacturing of three-dimensional (3D) composite-based objects is disclosed. The apparatus comprises a material feeder, a printer, a powder system, a transfer system, and optionally a fuser. The method comprises inserting a stack of substrate sheets into a material feeder, transferring a sheet of the stack from the material feeder to a printer, depositing fluid on the single sheet while the sheet rests on a printer platen, transferring the sheet from the printer to a powder system, depositing powder onto the single sheet such that the powder adheres to the areas of the sheet onto which the printer has deposited fluid, removing any powder that did not adhere to the sheet, optionally melting the powder on the substrate, and repeating the steps for as many additional sheets as required for making a specified 3D object.
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公开(公告)号：US20240278486A1
公开(公告)日：2024-08-22
申请号：US18648948
申请日：2024-04-29
发明人： Robert Swartz , Eugene Gore , Buckley Crist , Michael Vasquez , John Bayldon
IPC分类号： B29C64/147 , B29C64/153 , B29C64/165 , B29C64/245 , B29C64/295 , B29K23/00 , B29K25/00 , B29K33/00 , B29K71/00 , B29K79/00 , B29K81/00 , B29K101/10 , B29K105/00 , B29K707/04 , B32B5/02 , B32B5/26 , B33Y10/00 , B33Y70/00 , B33Y70/10 , B33Y80/00
CPC分类号： B29C64/147 , B29C64/153 , B29C64/165 , B29C64/245 , B29C64/295 , B32B5/022 , B32B5/024 , B32B5/26 , B33Y10/00 , B33Y70/10 , B33Y80/00 , B29K2023/06 , B29K2023/12 , B29K2025/06 , B29K2033/12 , B29K2071/00 , B29K2079/085 , B29K2081/04 , B29K2101/10 , B29K2105/0097 , B29K2707/04 , B29K2713/00 , B29K2995/0094 , B32B2260/023 , B32B2260/046 , B32B2264/10 , B33Y70/00
摘要： A three-dimensional object comprises stacked substrate layers infiltrated by a hardened material comprising engineered powder that is transformed into a substance that flows and subsequently hardens into the hardened material in a spatial pattern that infiltrates positive regions, and does not infiltrate negative regions, in the substrate layers. The powder may be emulsion aggregation powder, chemically-produced toner powder, or a combination. It may be a thermoplastic or thermosettable polymer and may include nylon, elastomers, polyolefins, polyethylene, polyether ether ketone, polyimide, polyetherimide, polyphenylene sulfide, polystyrene, polypropylene, polymethyl methacrylate, and polyaryletherketone, or a combination. The powder particles may have a pre-specified controlled shape and/or a non-homogenous composition. Surface treatments and/or additives may be used to control powder flow and charge distribution. Each substrate layer may be a sheet-like structure comprising fibers held together by binder. The binder may include sodium silicate.
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7.发明申请公开(公告)号：US20210291437A1
公开(公告)日：2021-09-23
申请号：US17198780
申请日：2021-03-11
发明人： Robert Swartz , John Bayldon , Buckley Crist , Eugene Gore
IPC分类号： B29C64/147 , B29C64/295 , B29C64/393 , B29C64/307
摘要： A method and apparatus for resistive heating usable in composite-based additive manufacturing is disclosed. The method includes providing a prepared stack of substrate sheets, placing the stack between electrode assemblies of a compression device, applying a current to thereby heat the stack to a final temperature to liquefy applied powder, compressing the stack to a final height, cooling the stack, and removing the cooled, compressed stack from the compression device. The apparatus comprises at least two plates, a power supply for providing current, a first electrode assembly and a second electrode assembly.
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公开(公告)号：US20210229355A1
公开(公告)日：2021-07-29
申请号：US17156540
申请日：2021-01-23
发明人： Robert Swartz , Leonard Wanger , John Bayldon , Drew Marschner , Michael Rohrer , Gintaras Vaisnys , Giovanni Meier
IPC分类号： B29C64/259 , B33Y40/00 , B33Y30/00 , B29C64/307 , B29C64/386 , B33Y50/00
摘要： A bulk ink bag system in a composite-based additive manufacturing process (CBAM) keeps the inkjet heads (cartridges) on printers filled to the proper level of fluid at all times while the process runs. The system includes gravity fed fluid delivery without requiring pumps; is simple to connect and disconnect to system plumbing; has the ability to change ink bags without interrupting the print job or introducing air bubbles into the ink supply; and has the ability to disconnect partially used bags and reconnect them later.
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公开(公告)号：US20240254344A1
公开(公告)日：2024-08-01
申请号：US18423920
申请日：2024-01-26
发明人： Robert Swartz , Michael Vasquez , Buckley Crist , John Bayldon , Eugene Gore
摘要： Processes for producing CBAM parts and/or components, including resulting articles, are disclosed. In one process, a fiber substrate binder possessing a flash point temperature greater than a predetermined processing temperature is used.
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公开(公告)号：US11969938B2
公开(公告)日：2024-04-30
申请号：US16775267
申请日：2020-01-28
发明人： Robert Swartz , Eugene Gore , Buckley Crist , Michael Vasquez , John Bayldon
IPC分类号： B29C64/147 , B29C64/153 , B29C64/165 , B29C64/245 , B29C64/295 , B29K23/00 , B29K25/00 , B29K33/00 , B29K71/00 , B29K79/00 , B29K81/00 , B29K101/10 , B29K105/00 , B29K707/04 , B32B5/02 , B32B5/26 , B33Y10/00 , B33Y70/00 , B33Y70/10 , B33Y80/00
CPC分类号： B29C64/147 , B29C64/153 , B29C64/165 , B29C64/245 , B29C64/295 , B32B5/022 , B32B5/024 , B32B5/26 , B33Y10/00 , B33Y70/10 , B33Y80/00 , B29K2023/06 , B29K2023/12 , B29K2025/06 , B29K2033/12 , B29K2071/00 , B29K2079/085 , B29K2081/04 , B29K2101/10 , B29K2105/0097 , B29K2707/04 , B29K2713/00 , B29K2995/0094 , B32B2260/023 , B32B2260/046 , B32B2264/10 , B33Y70/00
摘要： A three-dimensional object comprises stacked substrate layers infiltrated by a hardened material comprising engineered powder that is transformed into a substance that flows and subsequently hardens into the hardened material in a spatial pattern that infiltrates positive regions, and does not infiltrate negative regions, in the substrate layers. The powder may be emulsion aggregation powder, chemically-produced toner powder, or a combination. It may be a thermoplastic or thermosettable polymer and may include nylon, elastomers, polyolefins, polyethylene, polyether ether ketone, polyimide, polyetherimide, polyphenylene sulfide, polystyrene, polypropylene, polymethyl methacrylate, and polyaryletherketone, or a combination. The powder particles may have a pre-specified controlled shape and/or a non-homogenous composition. Surface treatments and/or additives may be used to control powder flow and charge distribution. Each substrate layer may be a sheet-like structure comprising fibers held together by binder. The binder may include sodium silicate.
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